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Doc. Rev.
ES-(XTJB)5,6-09-00-0025 2
Engineering Sheet No.

Date ：JUL.17.2019
Customer
Sumitomo Corporation

Project Prepared: K.Takenaga

TANJUNG JATI B EXPANSION(JAWA-4)
COAL FIRED STEAM POWER PLANT 2x1,000MW Checked: R.Eto
Subject
GENERAL ERECTION PROCEDURE FOR Approved: T.Masaki
BOTTOM ASH HANDLING SYSTEM

Content Page No.

1. Purpose 　(3/16)
2. Scope 　(3/16)
3. Materials / Equipments 　(4/16)
4. Loading / Unloading 　(4/16)
5. Flow Chart 　(6/16)
6. Installation
6.1 Preparation 　(7/16)
6.2 Installation 　(7/16)
7. Safety Plan 　(13/16)

　　　Attachment-1 Risk Assessment

　　　Attachment-2 Manufacture’s Drawing and Manual
Attachment-3 installation Plan

CONFIDENTIAL
THIS DOCUMENT IS THE PROPERTY OF SUMITOMO CORPORATION BOILER DIVISION (SCBD) AND CONFIDENTIAL. IT MUST
NEITHER BE COPIED NOR USED FOR ANY PURPOSE OR MANNER OTHER THAN EXPRESSLY PERMITTED BY MHPS OR WITH
A PRIOR WRITTEN CONSENT OF SCBD NEITHER IS IT TO BE HANDED OVER NOR COMMUNICATED TO A THIRD PARTY IN ANY
WAY. BREACH OR INFRINGEMENT OF ANY KIND WILL LEAD TO LEGAL ACTION.

SUMITOMO CORPORATION BOILER DIVISION

 ( 2 / 16 )
Doc.
Revisions No. ES-(XTJB)5,6-09-00-0025

Rev. Description Revised Checked Approved Date

0 First issue －- -
－ -
－ －

1 Revised as per customer’s comments K.Takenaga R.Eto

T.Masaki 04.SEP.2019

2 Revised as per customer’s comments

CONFIDENTIAL
THIS DOCUMENT IS THE PROPERTY OF SUMITOMO CORPORATION BOILER DIVISION (SCBD) AND CONFIDENTIAL. IT MUST
NEITHER BE COPIED NOR USED FOR ANY PURPOSE OR MANNER OTHER THAN EXPRESSLY PERMITTED BY SCBD OR WITH A
PRIOR WRITTEN CONSENT OF SCBD NEITHER IS IT TO BE HANDED OVER NOR COMMUNICATED TO A THIRD PARTY IN ANY
WAY. BREACH OR INFRINGEMENT OF ANY KIND WILL LEAD TO LEGAL ACTION.

SUMITOMO CORPORATION BOILER DIVISION

 ( 3 / 16 )
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1. Purpose

The purpose of this work plan procedure is to define the installation for the
Bottom Ash Handling System in Tanjung Jati B Expansion (Jawa-4) Coal Fired
Steam power Plant 2 x 1000MW. The work plan stated herewith is to ensure that
there is a guideline to be followed for the safe installation.

The necessity for safety precautions during the related must be emphasis.
Attention is therefore drawn to the established site safety procedure (refer to
TJB56-L2-ON-C-00-H-PLA HSE MANAGEMENT PLAN FOR CONSTRUCTION),
which should be adhering to under all practical and possible situation.

During safe of material loading / unloading and erection the contractor’s

supervisor or foreman will inspect the work from time to time in the presence of
contractor to establish conformity with the requirements of the specification.

2. Scope

This procedure covers the specification requirement, maker’s installation standard

and execution procedure for Bottom Ash Handling System construction for the
Tanjung jati B Expantion (Jawa-4) Project. This procedure however may not limit
the site installation supervisor to adopt slight variance from the process defined
herein due to site progress condition provided this is in line with the adhered
principle of compliance to specification requirement.

The scope covers the handling precautions, foundation layout, setting, alignment
and assembly of other components including inspections related to this
installation.

<Reference Document>
Please refer to documents in Attachment-1 to 3.

SUMITOMO CORPORATION BOILER DIVISION

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3. Materials / Equipments

Below is a general list of the equipment and tools that is required for unloading
and erection work.

a) Required lifting tools and tackles (slings, eyebolts, shackles, chain block,
lever block)
b) Timber or wooden block
c) Hiab truck 10T
d) Mobile Crane 80T
e) Trailer
f) 6t Forklift
g) Roller skid (Turtle Tank)
h) Electrical Winch 3T, 5T

4.Loading / Unloading

a) Place the required crane in good and rigid groud in out rigger in extended
position for hydraulic crane and truck mounted crane. For crawler crane the
parking area should be flat and good bearing strength.
b) For more precaution, place a suitable steel plate or timber mat on bottom of
the outer rigger.
c) Crane jack up (extend outrigger) at maximum position.
d) Check and confirm the level o the crane, before proceeding the unloading
work. (for all type of crane)
e) Swing the crane 360 degrees to confirm the four outrigger in good and stable
position (for telescopic types of crane)
f) Bring and position the trailer in such a way that, the chart working radius is to
be maintained. (for all type of crane)
g) Connect all the recommended lifting gears to the crane hook and lift it up.
h) Once all the lifting gears connected and swing the crane gently to check any
obstruction.
i) If any obstruction, remove it or clear the swing path.
j) If access not reachable to connect the lifting gears to material loaded
container, wooded cradle places an aluminum ladder in appropriate position
for the access of rigger to go top and connect the sling to the above said
packages.
k) Connect the lifting slings to the material loaded container, wooded cradle and
material package case lifting points mension in the case with the help of
shackles.
l) If the all above said method or procedure is accepted by the supervisor, give
the load to the crane and check it.
m) Be sure that, during swinging and lowering all the four outrigger in good
stable ondition.
n) Swing the crane as required and if the crane working radius is in correct,
lower the materials or packing.

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SUMITOMO CORPORATION BOILER DIVISION

 Doc.
No. ES-(XTJB)5,6-09-00-0025

o) Place the materials or packing on top of the timber block if available, and
sure that the materials or packing and timber block in fully contact.
p) After, the lifting supervisor inspected the rigidity, loose the sling and open it
from materials or packing lifting hook.
q) The crane shall be hooked up to the material as per the handing instruction.
r) The material shall be picked up by crane, keeping the material level, till it is
clear off the trailer.
s) The material shall be moved in position over the timber or wooden block and
lowered.
t) The material shall be lowered till it is positioned directly on the timber or
wooden block, and all final adjustments made while it is still hooked up to the
mobile crane.
u) When it is confirmed that material is properly positioned and the proper level.
v) Proceed to unload another materials or packing, container and wooden
cradle by the same safe working manner.
w) Materials which are unloading and load by fork lift (3T and 4.5T) take
precaution during the entire operation.

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SUMITOMO CORPORATION BOILER DIVISION
5. Flow chart

Conveyor-1 Conveyor-2
01 Erection of BA Transition Hopper
Steelwork and Body

02 Inner and Outer Heatshield Note;

installation The number shows the same item as
(by Boiler wrok) Chapter-5 in Attachment -2.

03 Erection BA Conveyor-1 Horizontal

Section

04 Erection of Support Structure for

BA Conveyor-1 Inclined Section

05 Erection of BA Crucher Plarform 14 Erection of BA Conveyor-2

and Steelwork Horizontal Section

06 Erection of BA Conveyor-1 Inclined 15 Erection of Support Structure for

Section BA Conveyor-2 Inclined Section

07-09 Erection of BA Hydraulic Unit, 16 Erection of BA Conveyor-2 Inclied

Divirter and Crusher Section

10 Erection of Jaw Gate with Metallic 17 Erection of BA Conveyor-2

Expansion Joint Connection Chute

11 Erection of Transition Hopper

Platform and Stair

12 Erection of Refractory Anchor and

Lining for Transition Hopper

13 Erection of Jaw Gate Refractory

Lining

18 Erection of Hydraulic Unit Pipe Works

19 Erection of Fabric Compensator

20 Erection of Chain & Flight Attachment

21 Erection of Control Panel and Electrical Equipment

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SUMITOMO CORPORATION BOILER DIVISION

6. Installation
6.1 Preparation
Basically, the foundation of the conveyor and structure should be rigid enough
to bear not only static and dynamic loads but also vibration of the
machine. The foundation is constructed with consideration of the ground
subsidence or sliding and rotating motions as well as vibration of the
machine sometimes cause unexpected troubles.

6.1.1 Foundation
a) Determine and mark the reference elevation for plant erection at any
position desired on the foundation, using for example, an alignment
scope.

b) Determine the centerlines for conveyor erection (X and Y direction) from the
reference line for plant erection and mark them on the foundation.

c) Check the location of foundation bolts with the foundation plan and the base
plate plan.

6.2 Installation
6.2.1 Transition Hopper Steelwork and body
a) Assemble the hopper supporting structure near the setting location
or outside the boiler mat whichever depending on the work area
conditions (assembly of 2 columns) 5.5m by 4.5m for erection. About
3.5Ton

b) The casing of the transition hopper is divided into upper, middle and
lower parts. Assemble the casing in suitable sized panels on the
ground and hang temporarily on the boiler buckstays and hopper
supporting structure.

c) Fitup the transistion hopper casing panels and weld accordingly

Refer to Fig-1

Typical Block-1 (2no.s) Typical Block-2 (4no.s)

Fig-1 Assembling Plan

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6.2.2 Inner and Outer heatshield Installation

a) Install the heatshield plate under the furnace hopper panel.
There is no problem even if it is installed later. Refer to Fig-2.
Furnace Inlet
Header
Inner &Outer Sheild
(Seal Plate)
Fablic Compensator

Transition Hopper
Casing

Fig-2 Heatshield (Hopper Seal)

6.2.3 Horizontal and Inclined BA Conveyor-1

a) Set the sole plate for conveyor-1.
Refer to Fig-3

Sole Plate

Anchor bolt

Fig-3 Sole plate

b) Assemble the horizontal conveyor-1 casing near the setting location

or outside the boiler mat whichever 　 depending on the work area
conditions, and carry it in to desgnate position according to the pre-
marked center line and connect the horizontal conveyor-1 casing.

6.2.4 Support Structure for BA Conveyor-1 Inclined Section

a) Install the supporting structure and platform for conveyor-1 inclined
section. Refer to Fig-4
6.2.5 BA Crusher Platform and Steel Work
a) Install the platform, handrail and beams according to equipment
installation.
Inclined section

Horizontal section
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 Supporting Structure Crusher Platform
Fig-4 Conveyor-1 Outline

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6.2.6 BA Conveyor-1 Inclined Section

a) Assemble the inclined conveyor-1 casing near the setting location or
outside the boiler mat whichever 　 depending on the work area
conditions, and carry it in to desgnate position according to the pre-
marked center line and connect the horizontal conveyor-1 casing.
b) Check the center and straightness of the casing from the tail to the
head based on the horizontal conveyor, and make final settings.

6.2.7 Hydraulic Unit, Diverter and Crusher

a) Set the hydraulic unit in the designated position, and pour grout.
When grout has set completely, tighten the anchor bols.
Location of hydraulic unit shown in Fig-5

Hydraulic Unit

Fig-5 Location of Hydraulic Unit

Reference drawing shown on Chapter-7 4.0 in Attachment-2.

b) Set the diverter and crusher. Refer to Fig-6

Diverter

Crusher

Chute between crusher and conveyor-2 is

installed after setting the conveyor-2.

Fig-6 Diverter & Crusher

Reference drawing shown on Chapter-7 5.0 & 6.0 in Attachment-2.

SUMITOMO CORPORATION BOILER DIVISION

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6.2.8 Jaw gate with Metallic Expansion
a) After setting of the conveyor-1 casing and transition hopper, set and
connect the jaw gate and metallic expansion.
Refer to Fig-7 and reference drawing shown on Chapter-7 7.0 in
Attachment-2.

Jaw gate and Metallic expansion

Fig-7 Jaw Gate

6.2.9 Transition Hopper Platform and Stair

a) Install the handrail, grating and stair around the Jaw gate and
transition hopper. (e.g. parts that are installed after the equipment is
installed)

6.2.10 Refractory Anchor and Lining for Transition Hopper

a) Assemble the scaffold inside transition Hopper clean the casing
surface.
b) Install the anchor pin according to the design drawing. And adjust the
anchor pin position approproately according to the hopper shape.
c) Attach the first layer of sillica boad and fill the gaps with mortar.
d) Install the formwork for refractory lining. Since the refractory is divided
into 2 to 3 installations, the size of the formwork shall be install that
can withstand the installation range and casting pressure.
c) Add water to the refractory material according to the manufacturer's
standard, mix it until the appropriate softness is obtained with a mixer,
and transport it with a pressure pump or bucket, and pour it into the
form
d) After pouring is complete, confirm the hardening of the refractory
material and remove the formwork

Refer to Chapter-7 8.0 in Attachment-2

6.2.11 Jaw Gate Refractory Lining

a) To prepare the refractory, add water to the refractory material
according to the manufacturer's standard, mix it until the appropriate
softness is obtained with a mixer, and transport it by bucket, and pour
it into the jaw gate.

Refer to Chapter-7 7.0 in Attachment-2

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6.2.12 Horizontal BA Conveyor-2
a) Assemble the conveyor-2 horizontal casing block and make
temporary setting on the foundation.
Refer to Fig-8

6.2.13 Support Structure for BA Conveyor-2 inclined Section

a) Install the supporting structure and platform for conveyor-2 inclined
section.

6.2.14 BA Conveyor-2 Inclined Section

c) Assemble the conveyor-2 block in an appropriate size that can be
transported and lifted on supporting structure.
Refer to Fig-8.
d) Check the center and straightness of the conveyor-2 casing from the
tail to the head, and make final connection and settings.
e)
Inclined Block-3
L8.5xW1.2xH1.3
Lot2
Lot2 Terminal Point

Inclined Block-2
L10xW1.2xH1.3m
Lot3
Lot3 Inclined Block-1
L12xW1.2xH1.3m

Horizontal Block

Ash silo (by Lot3)

Support Structure for Inclined Section
Fig-8 Conveyor-2

6.2.15 BA Crusher and Conveyor-2 Connection Chute

a) Install the connection chute between crusher to conveyor-2 (refer to
Fig-6) and conveyor-2 to ash silo. (refer to Fig-8)

6.2.16 Hydraulic Unit Piping

a) Install the oil piping from hydraulic unit to jaw gate.
b) Weld sockets and flange in accordance with such a procedure as
shown in a welding procedure.

SUMITOMO CORPORATION BOILER DIVISION

 c) At the time of pipe assembly, chek that there is no foreign material
inside the pipes and it shall be cleaned by air blowing with use of
compressed air if necessary.
d) Pneumatic leak check shall be performed to the pipeline after
assembled oil pipe line.

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6.2.17 Fablic Compensator
a) Install the fablic compensator according to the drawing.
Refer to Fig-9 and reference drawing shown on Chapter-7 9.0 in
Attachment-2

Furnace Inlet
Header
Inner &Outer Sheild
(Seal Plate)
Fablic Compensator

Transition Hopper
Casing

Fig-9 Fabric Compensator

6.2.18 Chain and Flight Attachment

a) Assemble chain and flight attachment for Conveyor-1 & 2.
Refer to Fig-10, 11.

Fig-10 BA Conveyor-1 Fig-11 BA Conveyor-2

6.2.19 Control Panel and Electrical Equipment

a) Install the control panel and electrical work for BA conveyor system
will be carried out.

SUMITOMO CORPORATION BOILER DIVISION

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7. Safety Plan
The general items related to work should follow the following HSE
management plan.

Doc.No: TJB56-L2-ON-C-00-H-PLA-0001
HSE MANAGEMENT PLAN FOR CONSTRUCTION

1) All workman from contractor that are involved in this operation, including
supervisors, foreman and operator etc. would be provided with the
required PPE such as safety helmets, harness, safety shoes, safety
glasses (goggles). As per the site laydown envilonment all crew would be
provided by dust mask and ear protection.
2) Prior to the operation or work, safety personnel shall ensure that all the
relevent safety permit are approved.
3) The lifting slings, chain blocks and shackles used shall have valid
statutory certificates.
4) Lifting supervisor and signalman from contractor will coordinate with
operator to ensure safety and smooth operation.
5) No un authorized personnel shall stand under any suspended load.
6) The chemical substances, paint materials, lubricant oil are kept in
separate area under hazards material sign board, no smoking sign
board.
7) The hazards material are kept in proper ventilated places.
8) Plan tools and equipment safety
a. The following four basic principles shall be applied to and govern the
safe use of hand power tools, and wich principles are,
 To choose the right tools for the job
 To use only tools in a good condition
 To use the tools correctly, and only for the purpose they were
intended
 To maintains and store tools properly

b. Electrical tools shall be checked to snusre the supplied voltages is

comparable to the machines design
c. Electrical leads and connections shall be connected to a single power
plug, where required for electrical tools shall be properly earthed.
d. House supplying air to pneumatic tools shall be inspected for signs of
wear or damage, and connecting clamps proved secure.

SUMITOMO CORPORATION BOILER DIVISION

 e. High speed rotaiting equipment, such as grinder shall be fitted with
protective gurads. Grinding discs are rated by the speed at whichh
the discs rotate, and this must be compatible with the rotational
speed of the grinder itself
f. Power tools shall never be left operating unattended.
g. Spark arrestor shall be fitted to all equipment exhausts where a risk
of combustible gases in the atmosphere exists.

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h. Scaffolding work
 Select only good & rigid scaffold component materials.
 Store scaffold material with proper racks / container and
barricade around the storage area with proper signage.
 Use only trained, competent and authorized scaffold erectors to
carry out work.
 Safety harness with 2 lanyards attached to a shock absorber
must be anchored to rigid member of existing scaffold at all time.
 Tie down all hand tools to part of body or to safety harness.

9) Lifting materials and equipment

Risk; Falling, load swinging, machine overtaking causes serious bodiely
injury

a. Lifting Crew
 Certified liftingsupervisor will oversee the lifting operations.
 Ceriffied rigger to do rigging of the loads.
 Certified signalman to do signaling during the lifting opeartions.
 Certified and licensed crane operator to operate the crane
 Certified lorry loader operator to operate lorry crane.

b. Machine Maintenance
 Daily pre-start checks to be done prior to commencing the work
 Pre-start checks also to be done when taking over from another
operator.
 All warnign devices to be checked and operating.
 Fallts of damaged to be reported
 Defects effecting safety to be reported immediately to the
supervisor.
 Plant with safety defects to be stood down until hazards is
rectified.
 Regular maintenance and servicing to be carried out in
accordance with manufacture’s specifications.
 Operators to read appropriate sections of the operation and
maintenance manual.

SUMITOMO CORPORATION BOILER DIVISION

c. Lifting Equipment
 Materials of lifting equipment must be of sound and suitable
material, adequate strengyh and free from plant defect.
 All lifting machine (crane, whinch, hoist, etc.), lifting appliances
(chain block, lever block, trolleys with pulley etc.) and lifting gears
(webbing slings, shackle, bow screw pin, wire rope, clamp,
locking hook etc.) shall be thoroughly tested and examined
annually by an approved persons. The certificate of test must be
vaild and maintained on site.

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 The register fo lifting machines, lifting appliances and

liftinggears used must be maintained on site.
 Implement monthly color coding system.
 Lifting equipment is to be inspected for damages, including
stretching and surface damage to links and nicks to slings, prior
to each use by the person slinging the load.
 Never combine different type of slings
 Shackles are to be used where slings are attached to eyebolts
or lugs.
 Multiple individual slings are to be shackled together on the
hook.
 Store fabric slings away from chemicals and proper stored to
be provided.
 Torn or damaged fabric slings are not to be used.

d. Slinging Methods for loads

 Lifting operation to be inspected and approved by the lifting
supervisor prior for all lifting activities.
 The slinging method is to be determined by the shape, size and
weight of each load
 Signalman to give correct and clear signal to guide the crane
operator in the maneuver of the load safely to its destination.
 Signalman to ensure or verify with the rigger that the load is
properly rigged up before he gives a clear signal to the crane
operator to lift the load.
 Where the crane operator may not be able to see cleasrly the
manual signals of the signalman,other means communication
e.g. radio should be used too.

e. Lifting Limits
 If the weight of the load is unknown, do not guess, but seek
further advice.
 Refer also to the load chart for load-reach relationship.
 No laods in excess of the safe working load shown on the load

SUMITOMO CORPORATION BOILER DIVISION

 chart are to be lifted.
 The load chart is to be kept in the cab of the machine at all times.

f. Slinging the Load

 Slings are to be positioned over flat surface not over sharp edges
or corners. Place adequate padding at the edges of the load,
which come in contact with the sling.
 The lifting area especially for heavy lift must be cordoned off and
prohibit unauthorized entry.
 Where a sling is used to hoist long and large materials, a lifting
beam must be used to space the sling legs for proper balance.

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 When a load is suspended at 2 or more points with slings, the

eyes of the lifting legs of the slings must be shackled together
and this shackle or the eyes of the shackled slings must be
placed on the hook. Alternatively, the eyes of the lifting legs may
be shackled directly to the hoisting block or blance beam.
 The lines (generally 16mm, natural fiber rope or equivalent) are
to be used as necessary to control load sway.
 Ensure all lifting attachment welds (e.g. lifting lugs) are safe for
during lifting operation.
 Make sure the load to be lifted is sesure, stable and blanced.
 Make sure no part of the load can slide or fail out during lifting.
 Ensure loose load including stones, bricks or tiles is placed in a
receptacles to prevent the load or part thereof from failing during
the lifting operations.
 Do not stand between the load and other obstructions.
 Keep hands and foot well clear of pinch points.
 Never leave load suspended without an operator at the control.
 Loads are not to be lifted over personnel during erection.
 Ensure that an adequate number of legs of the slings are used
and that the slinging angle is correct sa as to prevent the sling
from being overloaded during the hoisting.
 For large or long loads (12m+) attach 2 tagline controllers.

g. Travel with load

 Loads are to be kept as close to the ground as possible shilst
moved
 If unstable ground conditions or obstructions to travel are
present, the methods of controlling these hazards are to be
included in a specific Risk Assessment.
 Tag line controller to signal to operator when OK to lift/lower load
 Tag line controller to ensure no worker walks undeer the load or
boom or walks between the machine and the load.

SUMITOMO CORPORATION BOILER DIVISION

h. Lower Load
No person is to enter the exclusion zone until load 300mm from
ground.

SUMITOMO CORPORATION BOILER DIVISION